The present invention relates to acoustic wave devices.
Conventionally, an acoustic wave device including a piezoelectric layer made of lithium niobate or lithium tantalate is known.
Japanese Unexamined Patent Application Publication No. 2012-257019 discloses an acoustic wave device including a support body including a hollow portion, a piezoelectric substrate provided on the support body to overlap the hollow portion, and an interdigital transducer (IDT) electrode provided on the piezoelectric substrate to overlap the hollow portion, in which the IDT electrode excites a plate wave and the peripheral edge portion of the hollow portion does not include a straight line portion that extends parallel to the propagation direction of the plate wave excited by the IDT electrode.
International Publication No. 2013/146374 discloses a structure in which a plurality of acoustic wave elements are mounted on a mounting substrate by using a flip chip bonding method.
In the acoustic wave device described in International Publication No. 2013/146374, when the acoustic wave elements are mounted on the mounting substrate via bumps, a crack may occur in portions of the piezoelectric layer disposed directly under the bumps due to pressure or impact during mounting, and the crack may extend to an excitation portion including functional electrodes.
Example embodiments of the present invention provide acoustic wave devices in each of which an excitation portion including functional electrodes is less likely to be damaged when acoustic wave elements are mounted.
An acoustic wave device according to an example embodiment of the present invention includes an acoustic wave element, a plurality of bumps electrically connected to the acoustic wave element, an under-bump metal layer between the acoustic wave element and the bumps, a wiring substrate on which the acoustic wave element is mounted, and an encapsulating body covering the acoustic wave element on the wiring substrate. The acoustic wave includes element a support substrate, a piezoelectric layer on one main surface of the support substrate, and a functional electrode on at least one main surface of the piezoelectric layer. The wiring substrate is electrically connected to the acoustic wave element via the under-bump metal layer and the bumps. The piezoelectric layer includes a hole passing through the piezoelectric layer on at least a portion of a straight line connecting the functional electrode and the bumps to each other.
According to example embodiments of the present invention, it is possible to provide acoustic wave devices in each of which an excitation portion including functional electrodes is less likely to be damaged when acoustic wave elements are mounted.
The above and other elements, features, steps, characteristics and advantages of the present invention will become more apparent from the following detailed description of the example embodiments with reference to the attached drawings.
Acoustic wave devices according to example embodiments of the present invention will be described below with reference to the drawings.
In an acoustic wave device according to an example embodiment of the present invention, the piezoelectric layer includes a hole passing through the piezoelectric layer on at least a portion of a straight line connecting functional electrodes and bumps to each other. Accordingly, the growth of a crack in the piezoelectric layer produced during mounting can be reduced or prevented at the hole. As a result, an excitation portion including the functional electrodes is less likely to be damaged.
In the first, second, and third aspects of the present invention, an acoustic wave device according to example embodiments of the present invention include a piezoelectric layer that is made of, for example, lithium niobate or lithium tantalate and first electrodes and second electrodes that face each other in a direction intersecting the thickness direction of the piezoelectric layer.
In the first aspect, for example, a bulk wave of a thickness-shear mode, such as a first thickness-shear mode, is used. In the second aspect, for example, when first and second electrodes are adjacent to each other, d is the thickness of the piezoelectric layer, and p is the center-to-center distance between first and second electrodes, d/p is about 0.5 or smaller. As a result, in the first and second aspects, the Q value can be increased even when downsizing is achieved.
In the third aspect, for example, a Lamb wave is used as a plate wave. In addition, resonance characteristics of the Lamb wave can be obtained.
In a fourth aspect, an acoustic wave device according to an example embodiment of the present invention includes the piezoelectric layer made of, for example, lithium niobate or lithium tantalate and an upper electrode and a lower electrode that face each other in the thickness direction of the piezoelectric layer with the piezoelectric layer therebetween. In the fourth aspect, a bulk wave is used.
The present invention will be clarified by describing example embodiments of the present invention with reference to the drawings.
The drawings illustrated below are schematic, and the dimensions, the aspect ratios, and the like may differ from those of actual products.
Example embodiments of the present invention described in this specification are exemplary, and the structures of different example embodiments can be partially replaced or combined.
An acoustic wave device 10 illustrated in
Although not illustrated, one main surface of the support substrate 16 includes a wiring electrode that is electrically connected to the functional electrodes 15. In addition, the under-bump metal layer 13 is electrically connected to the wiring electrode.
When a hole that passes through the piezoelectric layer 19 is not provided on a straight line connecting the functional electrodes 15 and the bumps 12 to each other in the piezoelectric layer 19 as illustrated in
On the other hand, since the piezoelectric layer 19 includes the hole 24 that passes through the piezoelectric layer 19 on at least a portion of the straight line connecting the functional electrodes 15 and the bumps 12 to each other as illustrated in
The position of the hole 24 is not particularly limited as long as the hole 24 is provided on at least a portion of a straight line connecting the functional electrodes 15 and the bumps 12 to each other, but the hole 24 is preferably provided on a straight line connecting the functional electrodes 15 and the bump 12 closest to the functional electrodes 15 to each other as illustrated in
The number, the shape, and the size of the holes 24 are not particularly limited. When the number of the holes 24 is two or more, for example, the shape and the size of the holes 24 as viewed in a direction in which the support substrate 16 and the piezoelectric layer 19 are laminated together may be the same or different.
The wiring substrate 14 is electrically connected to the acoustic wave element 11 via the under-bump metal layer 13 and the bumps 12. The wiring substrate 14 is, for example, a printed wiring substrate. The coefficient of linear expansion of the printed wiring substrate is about 15 ppm/° C., for example. The printed wiring substrate is formed of a glass cloth/epoxy resin copper-clad laminated substrate, for example.
More specifically, the piezoelectric layer 19 of the acoustic wave element 11 is disposed with the main surface thereof facing the wiring substrate 14. The acoustic wave element 11 is mounted on external terminals 21 of the wiring substrate 14 via the bumps 12.
As a result, a space is provided between one main surface of the piezoelectric layer 19 and the wiring substrate 14. The functional electrodes 15 are provided between one main surface of the piezoelectric layer 19 and the wiring substrate 14.
More specifically, the external terminals 21, the bumps 12, the under-bump metal layer 13, the piezoelectric layer 19, and the support substrate 16 of the acoustic wave element 11 are laminated on the wiring substrate 14 in this order.
The bumps 12 can be made of a metal, such as Au, or an alloy, such as solder, for example. The bumps 12 are preferably made of Au, for example.
The wiring substrate 14 preferably includes vias 22. The vias 22 are provided in the wiring substrate 14. The wiring substrate 14 may include a plurality of external terminals 21, and in this case, preferably, the plurality of external terminals 21 are electrically connected to each other via the vias 22.
The acoustic wave element 11 on the wiring substrate 14 is encapsulated with an encapsulating body 23. The encapsulating body 23 is, for example, preferably a resin, and more preferably a material in which an inorganic filler, such as a metal, is mixed into a resin material, such as an epoxy resin, a silicone resin, a fluororesin, or an acrylic resin.
The piezoelectric layer 19 is made of, for example, lithium niobate (LiNbOx) or lithium tantalate (LiTaOx). In this case, the piezoelectric layer 19 may be made of, for example, LiNbO3 or LiTaO3.
In addition, the piezoelectric layer 19 is preferably made of, for example, a monocrystalline piezoelectric substance. Since a monocrystalline piezoelectric substance is more likely to crack along the crystal cleavage plane during mounting than a polycrystalline piezoelectric substance, the technical significance of example embodiments of the present invention becomes greater.
The monocrystalline piezoelectric substance can be analyzed by an X-ray diffractometer (XRD).
An XRD is a device that evaluates the crystal structure of a sample by irradiating the sample with an X-ray and measuring the diffracted X-ray emitted from the sample. Since the crystal structure can be evaluated, polymorphs with the same chemical formula, such as, for example, quartz, tridymite, cristobalite, and silica glass, which all have chemical formula SiO2, can be distinguished. In addition, the lattice constant and the crystallinity can be evaluated by evaluating the obtained position and width of the peak.
When the piezoelectric layer 19 is made of a monocrystalline piezoelectric substance, a straight line connecting the functional electrodes 15 and bumps 12 to each other is preferably parallel or substantially parallel to the cleavage direction (the direction parallel to the cleavage plane) of the piezoelectric layer 19. This can efficiently prevent a crack from growing along the crystal cleavage planes.
The support substrate 16 may include a hollow portion but need not have a hollow portion.
The support substrate 16 may include a dielectric layer (also referred to as an insulating layer or joint layer) 18 on one main surface on which the piezoelectric layer 19 is provided. For example, the support substrate 16 includes a support 17 and the dielectric layer 18 provided between the support 17 and the piezoelectric layer 19.
The dielectric layer 18 is made of, for example, silicon oxide (SiOx). In this case, the dielectric layer 18 is preferably made of, for example, SiO2. As a result, frequency-temperature characteristics can be further improved.
The material of the dielectric layer 18 is not limited to the material described above and may be, for example, silicon nitride (SixNy). In this case, the dielectric layer 18 may be made of, for example, Si3N4.
The support 17 is made of, for example, silicon (Si). The material of the support 17 is not limited to the material described above and may be, for example, a piezoelectric substance, such as aluminum oxide, lithium tantalate, lithium niobate, or quartz, ceramic, such as alumina, sapphire, silicon nitride, aluminum nitride, silicon carbide, zirconia, cordierite, mullite, steatite, or forsterite, a dielectric, such as diamond or glass, a semiconductor, such as gallium nitride, or a resin.
The under-bump metal layer 13 is made of a metal. The metal includes, for example, at least one of Al, Pt, Au, Ag, Cu, Ni, Ti, Cr, Pd, or alloys mainly including these metals.
Modifications of example embodiment 1 will be described below.
When the support substrate 16 includes the dielectric layer 18, the hole 24 passing through the piezoelectric layer 19 may extend to the dielectric layer 18 of the support substrate 16. As illustrated in
When two or more holes are provided, all of the holes may pass through the dielectric layer, or a hole that passes through the dielectric layer and a hole that extends to midway through the dielectric layer may be mixed. In addition, a hole that passes through only the piezoelectric layer without extending to the dielectric layer may be provided.
Preferably, the support substrate 16 includes the hollow portion 20 in one main surface thereof, the piezoelectric layer 19 is provided on one main surface of the support substrate 16 to cover the hollow portion 20, and the functional electrodes 15 are provided such that at least a portion thereof overlaps the hollow portion 20 as viewed in a direction in which the support substrate 16 and the piezoelectric layer 19 are laminated together.
The hollow portion 20 may be provided in a portion of the support substrate 16 or may pass through the support substrate 16. The dielectric layer 18 need not necessarily be provided. That is, the hollow portion 13 need only be provided between the support substrate 16 and the piezoelectric layer 19.
For example, the acoustic wave element 11 may be a transversely-excited film bulk acoustic resonator (XBAR) element. In this case, the functional electrode 15 includes an IDT (interdigital transducer) electrode provided on one main surface of the piezoelectric layer 19.
The hole 24 may communicate with the hollow portion 20. For example, when a sacrificial layer to form the hollow portion 20 is formed on the piezoelectric layer 19, an opening hole (a through-hole 28 used in a manufacturing method of the acoustic wave element described later) through which the sacrificial layer is removed may be the hole 24. This can reduce cost and improves layout flexibility.
When the support substrate 16 includes the dielectric layer 18, the hollow portion 20 may pass through or need not pass through the dielectric layer 18.
The hollow portion 20 may pass through the support substrate 16. In this case, the support substrate 16 may include or need not include the dielectric layer 18.
As illustrated in
As illustrated in
When the support substrate 16 includes the dielectric layer 18, the hollow portion 20 may pass through or need not pass through the dielectric layer 18.
The hollow portion 20 may pass through the support substrate 16. In this case, the support substrate 16 may include or need not include the dielectric layer 18.
An acoustic wave element defining the acoustic wave device according to an example embodiment of the present invention is manufactured by, for example, the following method. An example of a method of manufacturing the acoustic wave element in which the support substrate includes the hollow portion, which is an example of the acoustic wave element, will be described with reference to
As illustrated in
The piezoelectric substrate 25 is, for example, a substrate made of LiNbO3 or LiTaO3.
The material of the sacrificial layer 26 is an appropriate material that can be removed by etching, which will be described later. The material is, for example, ZnO.
The sacrificial layer 26 can be formed by, for example, the following method. First, a ZnO film is formed by, for example, a sputtering method. After that, resist coating, exposure to light, and development are performed in this order. Next, a pattern of the sacrificial layer 26 is formed by wet etching, for example. The sacrificial layer 26 may be formed by another method.
As illustrated in
For example, a SiO2 film is formed as the dielectric layer 18. The dielectric layer 18 can be formed by, for example, a sputtering method. The dielectric layer 18 can be flattened by, for example, chemical mechanical polishing (CMP).
As illustrated in
As illustrated in
As illustrated in
As illustrated in
As illustrated in
The thickness-shear mode and the plate wave will be described in detail below. The following description uses an example in which the functional electrodes are IDT electrodes. The acoustic wave device in the following example corresponds to the acoustic wave element according to an example embodiment of the present invention, and the insulating layer corresponds to the dielectric layer according to an example embodiment of the present invention.
The acoustic wave device 1 includes the piezoelectric layer 2 made of, for example, LiNbO3. The piezoelectric layer 2 may be made of, for example, LiTaO3. The cut-angle of LiNbO3 or LiTaO3 is, for example, a Z-cut but may also be a rotated Y-cut or an X-cut. The propagation orientation is preferably Y propagation and X propagation about ±30°. The thickness of the piezoelectric layer 2 is not particularly limited but is, for example, preferably about 50 nm or greater and about 1000 nm or smaller to effectively excite the thickness-shear mode. The piezoelectric layer 2 includes a first main surface 2a and a second main surface 2b that face away from each other. Electrodes 3 and electrodes 4 are provided on the first main surface 2a of the piezoelectric layer 2. Here, the electrodes 3 are an example of the first electrodes, and the electrodes 4 are an example of the second electrodes. In
In addition, in a direction orthogonal or substantially orthogonal to the length direction of the electrodes 3 and 4, a plurality of pairs each including an electrode 3 connected to one potential and an adjacent electrode 4 connected to the other potential are provided. Here, the electrode 3 and the electrode 4 are adjacent to each other so as to include a space therebetween without being in direct contact with each other. In addition, when electrode 3 and 4 are adjacent to each other, other electrodes 3 and 4 or electrodes connected to a hot electrode or a ground electrode are not disposed between the electrode 3 and 4. The number of pairs need not be an integer but may be 1.5, 2.5, or the like. The center-to-center distance between electrodes 3 and 4, that is, the pitch, is preferably about 1 μm or greater and about 10 μm or smaller, for example. The center-to-center distance between electrodes 3 and 4 refers to the distance between the middle of the width of the electrode 3 in the direction orthogonal or substantially orthogonal to the length direction of the electrode 3 and the middle of the width of the electrode 4 in the direction orthogonal or substantially orthogonal to the length direction of the electrode 4. In addition, when the number of electrodes 3 or electrodes 4 is two or more (when 1.5 or more pairs each consisting of an electrode 3 and an electrode 4 are present), the center-to-center distance between an electrode 3 and an electrode 4 is the average value of the center-to-center distances between electrodes 3 and 4 adjacent to each other of 1.5 or more pairs of electrodes 3 and 4. In addition, the width of the electrodes 3 and 4, that is, the dimension in the direction in which the electrodes 3 and 4 face each other is, for example, preferably about 150 nm or greater and about 1000 nm or smaller.
When a Z-cut piezoelectric layer is used in the present example embodiment, the direction orthogonal or substantially orthogonal to the length direction of the electrodes 3 and 4 is orthogonal or substantially orthogonal to the polarization direction of the piezoelectric layer 2. This is not applied when a piezoelectric substance of another cut-angle is used as the piezoelectric layer 2. Here, “orthogonal” is not limited to “strictly orthogonal”, and may also be “substantially orthogonal” (the angle formed by the polarization direction and the direction orthogonal to the length direction of the electrodes 3 and 4 is, for example, about 90°±10°).
The support 8 is laminated on the second main surface 2b of the piezoelectric layer 2 via the insulating layer 7. The insulating layer 7 and the support 8 have a frame shape and include cavities 7a and 8a as illustrated in
The insulating layer 7 is made of, for example, silicon oxide. However, for example, an appropriate insulating material, such as silicon oxynitride or alumina, other than silicon oxide can be used. The support 8 is made of, for example, Si. The plane orientation of Si on the piezoelectric layer 2 side may be (100), (110), or (111). The Si preferably has a high resistance of, for example, about 4 kΩ or more. However, the support 8 can also be made of an appropriate insulating material or semiconductor material. The material of the support 8 may be, for example, a piezoelectric substance, such as aluminum oxide, lithium tantalate, lithium niobate, or quartz, ceramic, such as alumina, magnesia, sapphire, silicon nitride, aluminum nitride, silicon carbide, zirconia, cordierite, mullite, or forsterite, steatite, a dielectric, such as diamond or glass, a semiconductor, such as gallium nitride.
The plurality of electrodes 3, the plurality of electrodes 4, the first busbar electrode 5, and the second busbar electrode 6 are made of an appropriate metal, such as Al, or an appropriate alloy, such as AlCu alloy, for example. In the present example embodiment, for example, the electrodes 3, the electrodes 4, the first busbar electrode 5, and the second busbar electrode 6 have a structure in which an Al film is laminated on a Ti film. An adhesive layer other than a Ti film may be used.
An AC voltage is applied between the plurality of electrodes 3 and the plurality of electrodes 4 for driving. More specifically, an AC voltage is applied between the first busbar electrode 5 and the second busbar electrode 6. As a result, it is possible to obtain resonance characteristics using a bulk wave of the thickness-shear mode that is excited in the piezoelectric layer 2. In addition, in the acoustic wave device 1, for example, d/p about 0.5 or smaller where d is the thickness of the piezoelectric layer 2 and p is the center-to-center distance of any one pair of adjacent electrodes 3 and 4 of the plurality of pairs of electrodes 3 and 4. Accordingly, a bulk wave of the thickness-shear mode is effectively excited, and good resonance characteristics can be obtained. More preferably, for example, d/p is about 0.24 or smaller and, in this case, an even better resonance characteristics can be obtained. When the number of electrodes 3 or electrodes 4 is two or more, that is, when 1.5 or more pairs each including an electrode 3 and an electrode 4 are present, the center-to-center distance p between an electrode 3 and an electrode 4 is the average distance of the center-to-center distances between electrodes 3 and 4 adjacent to each other.
Since the acoustic wave device 1 according to the present example embodiment has the structure described above, even when the number of pairs of electrodes 3 and 4 is reduced for downsizing, the Q value is unlikely to decrease.
This is because the resonator requires no reflectors on both sides and has less propagation loss. In addition, the reason why no reflectors are required is because a bulk wave of the thickness-shear mode is used. The difference between a Lamb wave used by a conventional acoustic wave device and a bulk wave of the thickness-shear mode will be described with reference to
On the other hand,
As described above, at least one pair of electrodes 3 and 4 is provided in the acoustic wave device 1, but the number of pairs of electrodes 3 and 4 need not be two or more because the wave does not propagate in the X direction.
That is, at least one pair of electrodes need only be provided.
For example, the electrodes 3 are connected to the hot potential, and the electrodes 4 are connected to the ground potential. However, the electrodes 3 may be connected to the ground potential, and the electrodes 4 may be connected to the hot potential. In the present example embodiment, at least one pair of electrodes is connected to the hot potential or the ground potential as described above, and no floating electrode is provided.
The length of the region in which electrodes 3 and 4 overlap each other in a direction orthogonal to the length direction of the electrodes 3 and 4, that is, the length of the excitation region C is about 40 μm, the number of pairs of electrodes 3 and 4 is 21, the center-to-center distance is about 3 μm, the width of the electrodes 3 and 4 is about 500 nm, and d/p is about 0.133.
The length of the excitation region C is the dimension of the excitation region C in a direction parallel or substantially parallel to the length direction of the electrodes 3 and 4.
In the acoustic wave device 1, the inter-electrode distance of a pair of electrodes 3 and 4 is the same or substantially the same among the plurality of pairs. That is, the electrodes 3 and the electrodes 4 are disposed at equal or substantially equal intervals.
As is clear from
When d is the thickness of the piezoelectric layer 2 and p is the center-to-center distance between electrodes 3 and 4, d/p is, for example, preferably about 0.5 or smaller, and more preferably about 0.24 or smaller in the present example embodiment, as described above. The reason will be described with reference to
As in the acoustic wave device having the resonance characteristics illustrated in
As is clear from
As described above, at least one pair of electrodes may be one pair, and in the case of one pair of electrodes, p is the center-to-center distance of adjacent electrodes 3 and 4. In addition, the number of pairs of electrodes is 1.5 or greater, p may be the average distance of the center-to-center distances between adjacent electrodes 3 and 4.
In addition, when there are variations in thickness d of the piezoelectric layer 2, an average value of the thicknesses may be used.
In the acoustic wave device 61, a pair of electrodes 3 and 4 is provided on the first main surface 2a of the piezoelectric layer 2. K in
In the acoustic wave device according to the present example embodiment, for example, MR≤about 1.75 (d/p)+0.075 is preferably met where MR is a metallization ratio that is the ratio of the area of adjacent electrodes 3 and 4 of the plurality of electrodes 3 and 4 to the area of the excitation region in which the adjacent electrodes 3 and 4 overlap each other as viewed in a direction in which the adjacent electrodes 3 and 4 face each other. In this case, a spurious response can be effectively reduced. This will be described with reference to
The metallization ratio MR will be described with reference to
When a plurality of pairs of electrodes are provided, MR may be the ratio of the metallized portions included in all excitation regions to the sum of the areas of the excitation regions.
In the region in ellipse J in
In this case, the spurious response can be reduced by adjusting the film thickness of the piezoelectric layer 2 and the dimensions of the electrodes 3 and 4.
The hatched portion on the right side of a dashed line D in
The hatched portions in
Accordingly, the range of the Euler angles in formula 1, formula 2, or formula 3 is preferable because the fractional bandwidth can be sufficiently wide.
An acoustic wave device 81 includes a support substrate 82. The support substrate 82 includes a recessed portion that is open toward the top surface thereof. The piezoelectric layer 83 is laminated on the support substrate 82. This defines the hollow portion 9. An IDT electrode 84 is provided on the piezoelectric layer 83 above the hollow portion 9. Reflectors 85 and 86 are provided on both sides of the IDT electrode 84 in the direction in which an acoustic wave propagates. In
In the acoustic wave device 81, a Lamb wave as a plate wave is excited by applying an AC electric field to the IDT electrode 84 above the hollow portion 9. Since the reflectors 85 and 86 are provided on both sides, resonance characteristics of the Lamb wave can be obtained.
As described above, acoustic wave devices according to example embodiments of the present invention may use a plate wave, such as a Lamb wave.
Alternatively, an acoustic wave device according to an example embodiment of the present invention may use a bulk wave.
That is, acoustic wave devices according to example embodiments of the present invention can also be applied to bulk acoustic wave (BAW) elements. In this case, the functional electrodes are the upper electrode and the lower electrode.
An acoustic wave device 90 includes a support substrate 91. The hollow portion 93 passes through the support substrate 91. A piezoelectric layer 92 is laminated on the support substrate 91. An upper electrode 94 is provided on a first main surface 92a of the piezoelectric layer 92, and a lower electrode 95 is provided on a second main surface 92b of the piezoelectric layer 92.
While example embodiments of the present invention have been described above, it is to be understood that variations and modifications will be apparent to those skilled in the art without departing from the scope and spirit of the present invention. The scope of the present invention, therefore, is to be determined solely by the following claims.
This application claims the benefit of priority to Provisional Application No. 63/278,146 filed on Nov. 11, 2021 and is a Continuation application of PCT Application No. PCT/JP2022/041922 filed on Nov. 10, 2022. The entire contents of each application are hereby incorporated herein by reference.
Number | Date | Country | |
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63278146 | Nov 2021 | US |
Number | Date | Country | |
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Parent | PCT/JP2022/041922 | Nov 2022 | WO |
Child | 18657882 | US |